Mike --
There is no "inexpensive way" to weld aluminum... the equipment required (TIG) is expensive.
If you're not going to 'invest' in the equipment - then you really don't have many options other than having someone else do it for you.
There is a torch welder - uses common gas - that they sell for doing sheet aluminum. Ron Covell sells it on his website I think.
The only other way is to put a spool gun on your MIG machine. But that is usually a "production" version of welding aluminum and really doesn't work that well for what "we" do - which is odd ball parts here and there as we need them.
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